Modeling and Analysis of Vibration-Induced Changes in Connector Resistance of High Power Electrical Connectors for Hybrid Vehicles

Abstract

High power connectors used in hybrid vehicles are exposed to vibrations that cause changes in connector resistance. When vibration starts, the connector resistance increases temporarily and oscillates. When vibration stops, the connector resistance returns to a value that is similar to the original state. In this paper, finite element models are developed to analyze this phenomenon and compared with experimental results. A two-dimensional finite element model was developed to predict the motions at any location of the connector system. A contact spring present between the female and male parts of the connector is modeled in three dimensions and used to analyze the time response. The analysis shows that the relative displacement is closely related to the changes of connector resistance during vibration, and the models can be used to improve connector design and ensure better performance and reliability.

Keywords:

• Contact resistance
• Finite element modeling
• Fretting
• High power connector
• Round pin connector
• Vibration

ACKNOWLEDGMENT

This work has been funded by LS Cable Company, Ltd. Without their strong support, this project could not have happened.

Notes

^#Communicated by J. McPhee.